OPTIMIZATION OF MECHANICAL ANISOTROPY OF COVER SHEETS TO MINIMIZE THE POLYTHICKNESS WHEN STRETCH-WRAP FORMING


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Abstract

Using the PAM-STAMP 2G software package, the authors carried out the computer simulation of the process of stretch-wrap forming of sheets with the varied mechanical anisotropy. To study the influence of mechanical anisotropy on polythickness, the authors used the central composite design that includes complete and fractional factorial experiments and a number of replicate experiments and depends on the number of factors. As the variable factors of the model, the following mechanical properties of the material were used: yield strength, flow limit, uniform elongation, and the Poisson’s rate.

After simulation of all variants of stretch-wrap forming, the regression analysis of the results was implemented and the mathematical model of polythickness dependence on the mechanical anisotropy was formulated. It is determined that to minimize the polythickness, it is necessary to position sheet workpiece in relation to the bed of press in such a way that the direction of stretch-wrap forming would be the same as the direction of maximum anisotropy index, and the transverse direction of the stretch-wrap forming would be the same as the minimum anisotropy index.

Using the known methods of searching the function global minimum, the authors determined the optimal mechanical anisotropy, which provides the minimum polythickness (19,62 µm) for the considering scheme of stretch-wrap forming of sheets made of 1441 aluminium-lithium alloy: yield strength – 430 MPa, flow limit – 280 MPa, uniform elongation – 14 %, the ratios of transverse deformation at the angle of 0° and 45° to the rolling direction – 0,65, at the angle of 45° – 0,35. The rolling direction is the same as the direction of stretch forming.

It is recommended to the enterprises to provide the input control not only according to the mechanical properties but according to the transverse deformation ratios as well because they influence greatly the obtaining of the required shape of the product.

About the authors

Sergey Viktorovich Surudin

Samara University, Samara

Author for correspondence.
Email: innosam63@gmail.com

PhD (Engineering), assistant of Chair of Pressure Metal Treatment

Россия

Yaroslav Aleksandrovich Erisov

Samara University, Samara

Email: yaroslav.erisov@mail.ru

PhD (Engineering), assistant professor of Chair of Pressure Metal Treatment

Россия

Ilya Nikolaevich Petrov

Samara University, Samara

Email: ilpetrof110895@yandex.ru

student of Institute of Space Rocket Engineering

Россия

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